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Motor Truck Engineering Handbook

Fourth Edition

James William Fitch

Published by: Society of Automotive Engineers, Inc. 400 Commonwealth Drive Warrendale, PA 15096-0001 U.S.A. Phone: (412) 776-4841 Fax: (412) 776-5760

Library of Congress Cataloging-in-Publication Data


Fitch, James William, 1910\x=req-\
Motor truck engineering handbook / James William Fitch. 4th ed. cm. p. Includes index. ISBN 1-56091-378-9 : $39.00 1. Trucks\p=m-\Design and construction. I. Title. TL230.F49 1993 629.224\p=m-\dc20 93-35469 CIP
\p=m-\

Copyright \s=c\

1994 Society of Automotive Engineers, Inc.

ISBN 1-56091-378-9 All rights reserved. Printed in the United States of America. Second printing. Permission to photocopy for internal or personal use, or the internal or personal use of specific clients, is granted by SAE for libraries and other users registered with the Copyright Clearance Center (CCC), provided that the base fee of $.50 per page is paid directly to CCC, 222 Rosewood Dr., Danvers, MA 01923. Special requests should be addressed to the SAE Publications Group. 1-56091-378-9/94 $.50 SAE Order No. R-125

Preface
Eternal vigilance in seeking more efficient and economical motor transportation must be everpresent to maintain the industry's enviable growth and stature. The trucking industry is continually faced with spiraling costs which must be offset by more efficient application of equipment through improved methods and concepts in transportation.

The industry must challenge and change these deterrents that limit its scope and potential growth through better utilization ofthe nation's vastly improved highway

systems.
New

manufacturers. standards for safer, faster and more reliable and efficient transportation. Intelligent Vehicle Highway Systems (IVHS) technology will enhance increased efficiency and improved traffic management, and the trucking industry will become the first beneficiary. In the future, environmental concerns will influence these designs and operations. Rising public concern about automotive safety and environmental
matters

technologies

increased demands on owners, operators and must ultimately lead to radically improved vehicle These demands
are

pressing

prompts congressional demands for cleaner air and safer more efficient

vehicles. The major challenges facing our industry during this decade will be energy and the environment with continued improvement in safety and conservation. Mobile technology will continue to improve and meet the economic requirements of manufacturers, owners and operators.
Motor transport leaders will find this handbook significantly helpful and above all useful in coping with these problems. Motortruck executives have an unprivileged

responsibility to assure that motor vehicles are operated on the highways in a safe and efficient manner so as to reflect credit on both the industry and the operators.
This handbook will also serve as a ready reference for motor truck data and solutions to many motor vehicle problems. The trucking industry must create a

favorable image by keeping the general public as well people better informed on the values of its many services.
more

as

governmental

The fourth edition updates the basic truck engineering data from previous editions and introduces the latest advancements in electronic applications to truck power trains and operations, assuring optimum performance and economy with a safer and cleaner environment.

Useful data from official government tests on anti-lock brakes and traction enhance this edition. Likewise, environmental concerns are addressed through the use of non-polluting vehicles using alternative fuels and electrical energy.
This handbook is dedicated to my many friends in the industry who have so generously given of their time and specialized knowledge to help make this book more informative, more authoritative and more readable.
JWF

Table of Contents
Chapter I
THE TRUCKING INDUSTRY.1 Industry scope and truck facts. Registrations, revenues. The state of the art. Fundamentals of Metrics. IVHS.

Chapter n

SELECTING THE SIZE AND TYPE OF VEHICLE.15 Importance of proper selection for greater profits. Fundamentals for proper selection including charts and diagrams. Advantages of longer combinations. Federal and state legal size and weight regulations. Vehicle weight distribution for maximum payloads. Industry and S AE standards for vehicle dimensions. International size and weight regulations.
ROAD PERFORMANCE.57 Significance of torque and horsepower. How to determine vehicle performance, speed, gradeability, acceleration and metrication of same. Factors affecting vehicle performance, performance charts, tables, formulas. Power and traction.
FUEL ECONOMY AND OPERATING COSTS.83 Factors affecting fuel economy including engine design, lightweight materials, aerodynamics, radial tires, electronics, transmissions and rear axle ratios, driver ability and vehicle configuration. Operating and ownership costs. Fuel cost and maintenance, taxes and depreciation.

Chapter III

Chapter IV

Chapter V

CHASSIS COMPONENTS.109 Vehicle frames, cooling systems, supporting equipment including lightweight components, electronic equipment, air shields, air cleaners and exhaust systems. Fasteners.

Chapter VI

engines, turbochargers and charge air cooling. Analysis of Cummins, Mack, Detroit and Caterpillar engines. Dual fuel engines, dedicated fuel engines, methanol, CNG, LPG, electric battery power. Electronic engines, performance and fuel
economy.

ENGINE TYPES.125 Diesel and gasoline power for heavy-duty vehicles. Factors affecting fuel efficiency. High torque concept and low rpm

Chapter VII TRANSMISSIONS.169 Scope and function of powertrain. Mating transmission and rear axle ratios. Selecting gear reductions for optimum performance. Determining proper gear splits. Analysis oftruck gearing combinations, charts and tables. Selecting main and auxiliary transmission combinations. Transmissions for high torque and low rpm, fuel-efficient engines. Torque convertEaton CEEMAT Automatelectronic integration, gear-fast/run-slow concept, Allison ics, World automatic transmissions.
ers and automatic transmissions.

Chapter VDI

REAR AXLES.207

Operating factors influencing selection. Gearing for optimum fuel economy. Selecting axle types for desired performance. Functions and advantages of single and double reduction two-speed axles and tandems. Performance charts

for axles and transmission combinations. Axle ratios for lowrpm engines. Tri-drives and planetary axles. New Eaton Rockwell types, self-steering lift axles.

Chapter IX

AXLE SUSPENSIONS.225 Concept, function and application. Factors influencing selection of spring, rubber, air or solid-type suspension. Cost and weight savings. Ride and control considerations. Third axle and tri-axle suspensions. New Hendrickson suspensions, air suspension for lift axles. Electronic suspensions.

Chapter X

BRAKES AND RETARDERS.239 Requirements for adequate braking and vehicle control. Service and emergency brakes. Types and function of control valves. Federal and state braking regulations. Conditions affecting vehicle control and directional stability. Braking theory and application. Determining deceleration and stopping distances. Federal brake standards. ABS/NHTS brake test and configurations, ABS braking systems, types and makes of retarders, compression, exhaust, fluid, electric. DRTVETRAINS AND DRIVELINES.301 Concept and purpose. Requirements for efficient power transmission. Driveline thrust and torque considerations. Determining proper driveline angularity, torque rating and critical speeds. Constant velocityjoints. Noise and vibration control. Driveline components, advantages of integrated electronics, drivetrains.
STEERING GEOMETRY.317 Fundamentals governing good steering design. Factors and adj ustments affecting steering geometry and front-drive axes. Types and application of power steering. Determining turning radii and off-tracking for single and combination vehicles. WHEELS AND THS.335 Cast spoke or disc wheel selection. Factors influencing size and type of tires. Effects of inflation pressures and loads on tire life. Types of tires and applications. Radiais and low profile tires. Tire treads for better braking and stability. Hydroplaning. Steel studded tire advantages. Hub and stud pilot wheels. Tire capacity and ratings. Tire coefficients of friction.

Chapter XI

Chatper XII

Chapter XTO

Chapter XTV

ALTERNATIVE FUELS.357 Available alternative fuels, ethanol, methanol, reformulated fuels, compressed natural gas (CNG), natural gas, electric energy. Emissions, fuel economy, costs of converting, dual fuel operation, various engine conversions, dedicated engines. Electric vehicles, solar power, gasoline engines, LP gas engines, gas turbines, steam power. ENVIRONMENTAL REGULATIONS.377 Clean Air Act, emission regulations, air contaminants and sources, emission limits for heavy-duty trucks, EPA emission controls, smoke standards, Federal and state noise standards. Reducing vehicle noise. Vehicle tests, charts and tables.

Chapter XV

Appendix
Glossary
Index

Weights and measures (English-Metric).395

Terms and abbreviations used in the trucking industry.405

435

ISBN:978-0-7680-2417-3 Copyright 1993 SAE International

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